Electrical connector interfacial seals

ABSTRACT

An interfacial seal for an electrical connector for use between electrical connector interfaces. The environmental seal is formed of a resilient material and mounted on one of the connectors. A rear portion of the seal is fixed to the connector member. Upon mating, the front portion of the seal forms a sealing surface between the connector members and an intermediate portion of the seal collapses outwardly. The intermediate and forward portion of the seal may be initially tubular in shape and surround the contacts of one of the connector members. Moreover, a groove may be formed on the inner surface of the tubular members which provides a relief.

United States Patent Upstone et al.

[451 July 18, 1972 [54] ELECTRICAL CONNECTOR INTERFACIAL SEALS [72] Inventors: Harlan R. Upstone, Arcadia; Edward C.

Paugh, Hacienda Heights, both of Calif.

21 Appl. No.: 14,379

Wright 2,567,727 9/1951 Quackenbush ..339/75 R 3,005,971 10/1961 Lennox ....339/94 L 3,210,717 10/1965 Brown ..339/36 Primary Examiner-Joseph H. McGlynn Attorney-C. Cornell Remsen, Jr., Walter J. Baum, Paul W. Hemminger, Charles L. Johnson, Jr. and Thomas E. Kristofferson 57] ABSTRACT An interfacial seal for an electrical connector for use between electrical connector interfaces. The environmental seal is formed of a resilient material and mounted on one of the connectors. A rear portion of the seal is fixed to the connector member. Upon mating, the front portion of the seal forms a sealing surface between the connector members and an intermediate portion of the seal collapses outwardly. The intermediate and forward portion of the seal may be initially tubular in shape and surround the contacts of one of the connector members. Moreover, a groove may be formed on the inner surface of the tubular members which provides a relief.

6 Clains, 5 Drawing Figures Patented July 18, 1972 3,678,441

2 Sheets-Sheet l I in;

INVENTORS H/QRLAA/ R. (/PfiTQA/E ELECTRICAL CONNECTOR INTERFACIAL SEALS The invention relates in general to electrical connector interfacial seals and, more particularly, to an environmental seal for use between electrical connector interfaces.

BACKGROUND OF THE INVENTION Interfacial sealing components, particularly those used between the mating faces of electrical connectors are used to isolate individual circuits from the detrimental effects of otherwise degrading environments.

Typically harmful environmental conditions include moisture, salt spray, sand, dust, fluids as well as fumes. To overcome these and other environmental factors from being transmitted from one area of equipment to another area through connectors, electrical interfacial seals have been used to provide the necessary isolation desired. Conventional interfacial'seals function primarily by means of compressive forces which are formed when two connector halves are mated. Typically conventional environmental seals include flat gaskets while other types utilize projecting surfaces to effect localized compressive loading when the two connector halves are mated. The 'later mentioned projecting surface seal is generally considered the most reliable type of seal and may be considered to operate in the same fashion as does a cork in a bottle.

However, the most significant deficiency in the aforementioned seals is the inability of these seals to maintain sealing overa wide range of engagement lengths, that is, the distance between engaging faces. While conventional cable to box, cable to wall, or cable to cable connectors are generally held in close mating relationship through the function of their builtin coupling components, rack and panel type connectors must function over a much wider span of interfacial spacings. This wide spacing range is due to the fact that one-half of the connector is mounted in an equipment rack whereas the mating connector is mounted on the equipment box. Because of the structural characteristics of such installations a wide variation in connector mounting surfaces results with considerably larger variations between connector faces than occurs with other connector installations.

In order to overcome the attendant disadvantages of prior art environmental seals wherein the connector halves are subjected to a broad spectrum of spacings, the present invention provides a highly efficient reliable environmental seal. The seal provides maximum environmental protection which is effective throughout a broad spectrum of spacings between the connector halves. Moreover, the force per unit length of deflection of the seal can be controlled to values significantly less than conventional seals. The seal can be used where each connector contains a plurality of pin and socket contacts. Moreover, the seal is readily removable and replacable should damage thereto occur.

SUMMARY OF THE INVENTION The invention comprises an electrical connector assembly having an environmentalseal between a pair of mating interfaces of a first connector member and a second connector member. Each of the connector members having axially extending forward portions which are adapted to mate with one another and form a mated connector assembly. The environmental seal is formed of a resilient material and is mounted on one of the connectors. The seal has a rear portion generally fixed on the connector member, an intermediate portion extending forwardly from the rear portion mounted adjacent the forward portion of the one connector members, and a front edge surface which abuts an opening in the other of the connector members upon mating and forms a sealing surface therebetween. The opening in the other connector member is fixed relative to the rest of the other connector member, with the intermediate portion collapsing outwardly upon mating of the connector members.

The advantages of the invention, both as to its construction and mode of operation, will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings in which like referenced numerals designate like parts throughout the figures.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. I illustrates a perspective view, partly in section, of a male and a femaleconnector prior to mating utilizing the novel environmental seal in accordance with the invention;

FIG. 2 depicts male and female connectors of FIG. I partly in section partially mated;

FIG. 3 depicts the male and female connectors of FIG. 1 partly in section with the connectors fully mated;

FIG. 4 illustrates an alternative embodiment of the seal shown in FIG. I, partly in section, prior to interconnection of the connector halves; and

FIG. 5 illustrates the insulating seal of FIG. 4, partly in section, in a position wherein the connector halves are fully mated.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to the drawings there is shown in FIG. 1 a connector assembly 12 having a plug connector l4 which is to be mated with a receptacle connector 16. The plug connector 14 comprises an outer shell 22 which is champfered at its front outer surface 24 and contains an outwardly extending flange 26 at its rear outer surface. The inner surface of the shell 22 contains a front bore surface 28 which terminates at an inwardly extending flange 32 having a forward facing shoulder 34 and a rearward facing shoulder 36. The shell 22 further contains a rear bore surface 38 which terminates at the rearward facing shoulder 36 of the flange 32.

Mounted with the shell 22 is a front insulator member 42 whose outer dimensions are slightly less than the inner dimensions of the flange 32. The insulator 42 contains a plurality of bores 44 which terminate with a forward facing flared portion 46. The rear end of the bore 44 is adjacent an enlarged circular bore portion 48 with the junction of the bores 44 and 48 defining a rearward facing shoulder 52. A rear bore portion 54 is slightly greater in diameter than the bore 48 with the junction of the bores 48 and 54 being defined by a rearward facing shoulder 56.

Mounted in the bore portion 38 of the shell 22 is a rear insulator member 62. The front face 64 of the insulator 62 abuts the rearward facing shoulder 36 of the shell and the rear face 66 of the insulator 62 is flush with the rear surface of the flange 26. A retaining ring 68 whose outer dimensions are greater than the bore 38 and whose inner dimensions are less than the outer dimensions of the insulator 62 is utilized to maintain the insulator 62 in the bore 38. The insulator 62 contains a plurality of forward bores 72 axially aligned with the bores in the front insulator 42. The bores 72 terminate in a forward facing shoulder 74. The insulator 62 further comprises rear bores 76 which terminate at the shoulder 74. Electrical socket contacts 82 are mounted within the insulators 42 and 62 and contain a front contact portion 84 having a bore 86 therein. The front contact portion is integral with an enlarged cap portion 88 which abuts the rearward facing shoulder 56. The rear surface of the cap 88 is mounted flush with the interfacing surfaces of the front and rear insulators 62. A crimping cup 92 of the contact 84 is integral with the cap 88. The crimping cup 92 is mounted in the front bore 72 of the rear insulator 62. Extending rearwardly through the rear bores 76 are conductors 94 whose wires 96 have been crimped to the crimping cup 92.

The receptacle connector 16 comprises an outer shell 102 having an outwardly extending flange 104 formed along the front outer surface thereof. The shell 102 has a champfered front surface 106 whose rear terminates at an enlarged forward bore portion 108. The rear end of the forward bore portion terminates in a forwardly facing shoulder 112. An inwardly extending flange portion 114 is defined at its front surface by the forward facing shoulder 112 and in its rear surface by a rearward facing shoulder 116. A reduced diameter rear bore 118 is formed from the rear end of the shell 102 to the rearward facing shoulder 116. Abutting the rearward facing surface 122 of the shell is an annular retaining ring 124 whose outer surface is flush with the outer surface of the conductive shell 102 and whose inner dimensions are slightly smaller than the bore 118.

Mounted at the rear end of the conductive shell 102 is a rear insulator 126 which is held within the shell by means of the retaining ring 124. The rear surface 128 of the insulator 126 is flush with the rear surface 122 of the shell 102 and the front surface 130 terminates rearwardly of the rearward facing shoulder 116. The rear insulator contains reduced diameter rearward bores 132 and enlarged diameter forward bores 134, with a forward facing shoulder 136 defining the junction of the bores. A front insulator 142 has its front surface 144 positioned flush with the forward facing shoulder 112. The forward outer surface 146 of the insulator 142 is slightly less than the inner dimension of the flange 114 and the rear portion thereof is slightly less than the bore 118 and contains a forward facing shoulder 152 which abuts the rearward facing shoulder 116 of the shell 102. Further, the rear surface 154 of the front insulator 142 abuts the front surface of the rear insulator 126. The front insulator 142 further contains a plurality of enlarged rear bores 162 and a reduced diameter forward bore 164. Thejunction ofthe bores 162 and 164 define a rearward facing shoulder 166.

An interfacial seal 172 which is normally made of a resilient elastomer containing silicone, or other similar resilient material, has a rear surface 174 which abuts the front surface 144 of the front insulator 142. The seal contains a plurality of forwardly extending tubular portions 176 which extend from the front face 178 of the seal, Each of the tubular portions contain a bore 182 which extends from the front end of the tubular portion through to the rear surface 174 of the seal, the bores 182 being axially aligned with the bores of the front insulator 142 and the rear insulator 126. Further, an annular opening 184 is formed approximately in the center of the tubular portion along the surface of the bore 182.

Pin contacts 186, having a front contacting surface 188 for mating with the socket contacts 84, are mounted in the receptacle shell 102. The pin contacts extend forwardly of the tubular seal portion 176 and the rear end of the contacts terminate at a cap member 192 which is mounted in the bore 162 of the front insulator 142. The rear surface of the cap 192 is flush with the rear surface of the front insulator 142 and the front surface of the cap 192 abuts the rearward facing shoulder 166. The pin contact portion 188 extends forwardly from the front end of the cap member 192 and is seated in the bore 164 of the front insulator 142 and the bore 182 of the seal 172. A crimp cup 194 is mounted in the bore 134 of the rear insulator 126 and the front end thereof is integral with the rear surface of the cap 192. The rear end of the cup 194 abuts the forward facing shoulder 136 formed in the insulator 126. Conductors 196 have wires 198 therein, the wires being crimped to the crimp cup 194 with the conductors being positioned in the bore 132 of the rear insulator 126.

As the pair of mating connectors 14 and 16 are joined together, as shown in FIG. 2, the pin contacts 186 enter the contact portion 84 of the socket contacts. Further, the front end of tubular portion 176 abuts the flared portion 46 of the insulator 42 and continued mating of the connectors as shown in FIG. 3 allows the desired seal to form between the mating connectors. Moreover, the annular opening 184 of the bore 182 provides an internal relief for the seal and allows the seal to deflect outwardly along a plane of the opening with lower sealing forces.

Referring now to FIGS. 4 and there is shown an alternative embodiment of the interfacial seal but with the internal relief opening omitted. The seal 200 is formed of a forward facing surface 202 and tubular portion 204 extending therefrom. A bore 206 is formed in the tubular portion. The front end 208 of the tubular portion enters the flared portion 46 of insulator 42 upon mating causing the tubular portion to collapse outwardly radially along the axis of the connectors.

As can readily been seen, scaling is achieved in both embodiments at the junction of the front opening of the insulator 42 and the tubular front end of the sealing member. Thus, the seals are made effective over a broad spectrum of spacings between the connectors. As the mating distance decreases the seal expands into the open area between members, but due to the recovery characteristics of the material, the seal will continue to function as mating distances increase again. Thus, any inherent tendencies for mated distances to change under vibration, loading, temperature, expansion, contraction, or change in alignment conditions will be compensated for by the resilient recovery characteristics.

Further, it should be understood that individual tube seals could be used rather than the arrangement wherein the tubular members are all joined together by a common portion.

What is claimed is:

1. An electrical connector assembly having an environmental seal between a pair of mating interfaces of a first connector member and a second connector member, each of said connector members having axially extending forward portions which are adapted to mate with one another and form a mated connector assembly;

said environmental seal being formed of a resilient material and being mounted on one of said connectors, said seal having a rear portion generally fixed on said connector member, an intermediate portion extending forwardly from said rear portion and mounted adjacent the forward portion of said one connector members and a front edge surface which abuts an opening in the other of said connector members upon mating, and forms a sealing surface therebetween, the opening in said other connector member being fixed relative to the rest of said other connector member, said intermediate portion collapsing outwardly upon mating of said connector members.

2. An environmental seal for a pair of mating connectors, each of said connectors having a plurality of electrical contacts at least a portion of which is mounted in an insulator block; said contacts in one of said connectors being adapted to be mated with the contacts in the other connector; said seal having a rear portion which is generally fixed to a front surface of one of said insulator blocks and a plurality of intermediate portions and front portions, said intermediate and front portions being tubular in shape and having an inner surface which surrounds said contacts of one of said connectors;

the insulator block of said other connector having openings formed at the entry of a bore having its contacts mounted therein with the portion of said other insulator block containing said openings being fixed relative to said contacts; said front end portions of said seal engaging said openings upon mating of said connector shells, while said intermediate portion collapses as said connectors are drawn closer together.

3. An environmental seal in accordance with claim 2 wherein a groove is formed on the inner surface of said intermediate portion, said intermediate portion collapsing along the plane of said groove.

4. An environmental seal in accordance with claim 2 wherein said rear portion is formed of a surface which covers at least the entire front surface of said insulator block to which it is mounted.

5. An environmental seal in accordance with claim 2 wherein said intermediate portion collapses generally radially along the axis of said connectors.

6. An environmental seal in accordance with claim 2 wherein said seal will provide an effective seal over a range of distances between said connectors. 

1. An electrical connector assembly having an environmental seal between a pair of mating interfaces of a first connector member and a second connector member, each of said connector members having axially extending forward portions which are adapted to mate with one another and form a mated connector assembly; said environmental seal being formed of a resilient material and being mounted on one of said connectors, said seal having a rear portion generally fixed on said connector member, an intermediate portion extending forwardly from said rear portion and mounted adjacent the forward portion of said one connector members and a front edge surface which abuts an opening in the other of said connector members upon mating, and forms a sealing surface therebetween, the opening in said other connector member being fixed relative to the rest of said other connector member, said intermediate portion collapsing outwardly upon mating of said connector members.
 2. An environmental seal for a pair of mating connectors, each of said connectors having a plurality of electrical contacts at least a portion of which is mounted in an insulator block; said contacts in one of said connectors being adapted to be mated with the contacts in the other connector; said seal having a rear portion which is generally fixed to a front surface of one of said insulator blocks and a plurality of intermediate portions and front portions, said intermediate and front portions being tubular in shape and having an inner surface which surrounds said contacts of one of said connectors; the insulator block of said other connector having openings formed at the entry of a bore having its contacts mounted therein with the portion of said other insulator block containing said openings being fixed relative to said contacts; said front end portions of said seal engaging said openings upon mating of said connector shells, while said intermediate portion collapses as said connectors are drawn closer together.
 3. An environmental seal in accordance with claim 2 wherein a groove is formed on the inner surface of said intermediate portion, said intermediate portion collapsing along the plane of said groove.
 4. An environmental seal in accordance with claim 2 wherein said rear portion is formed of a surface which covers at least the entire front surface of said insulator block to which it is mounted.
 5. An environmental seal in accordance with claim 2 wherein said intermediate portion collapses generally radially along the axis of said connectors.
 6. An environmental seal in accordance with claim 2 wherein said seal will provide an effective seal over a range of distances between said connectors. 